Note: For best results read the Troubleshooting/Tips page prior to printing your 3D model. Problem: The .STL file will not open, or when it does it is incorrect, such as a bunch of random points everywhere. Solution: Verify that the .STL file was created from Revit, 3D CAD or FormZ.
Problem: When I printed the model it broke easily. Solution: The electronic model should be created to the dimensions you actually want the final product. Try to avoid scaling, though if scaling is required, scale the model before converting to a .STL format. Try to draw all parts of the models to at least 1/16” thick – and thicker if it supports the structure.
Problem: The model turned yellow after I finished it. Solution: For the FDM Process: Ensure that the ultrasonic bath is clean. For the ZCorp Printer: Use Z-Bond 101 to finish the model for best results and use a light coat for best results. If you choose to use clear spray paint, use a light coat to prevent discoloration.
Problem: My support structure did not completely dissolve in the ultrasonic bath. Solution: Use an exacto-knife to cut away the remaining supports. It is also recommended breaking away the non-intricate supports prior to the ultrasonic bath.
Frequently Asked Questions (FAQ's):
Q: How much does it cost to construct a model?
A: The FDM process cost $8.00/in3. The ZCorp Printer cost approximately $4.00/in3 (it is a function of the binder quantity).
Q: How long does it take to construct the model?
A: The FDM process takes approximately 45 minutes/in3 of model, and then another 45 minutes/in3 in the ultrasonic bath. The ZCorp Printer takes approximately 4 hrs to construct an 8” x 8” model.
Q: What is the benefit of using this technology over, let's say, chipboard model construction?
A: The 3D printing technologies allow for smaller model construction capabilities directly from CAD models, saving time and providing better results. The smaller construction tolerances of 0.004 inch is beneficial for constructing smaller building models that are to be a part of a site plan, also to provide greater detail on a larger sized model, allowing for the window sills, mullions, roof details, stairs, etc... to be constructed.
Contact Information:
For additional information on the ZCorp Printing process, including printing availability and costs, please contact the following:
Jamie Heilman
Architecture Department
0128 Stuckeman Family Building jrh225@psu.edu
For additional information on the FDM Printing process, including printing availability and costs, please contact the following:
Carson M Baird
Engineering Department
Superviser of Engineering Labs
0101 Engineering Services cxb290@psu.edu
For additional information on the Wikispaces used to create this website, please contact the following:
Dragana Nikolic
Architectural Engineering Department
Grad Student
Engineering Unit B dun113@psu.edu
Welcome to the Digital Fabrication Page for AE 597F
I. Introduction/Background
What is Rapid Prototyping?
Rapid Prototyping Technologies on Campus
(click on the links below for a process overview)- Fused Deposition Modeling (FDM)in the Learning Factory
- 3-D Printing in the Stuckman Family Building (SALA)
- Stereolithography Apparatus (SLA) in the Leonhard Building
The Basic RP Process WorkflowII. Step By Step Workflow Guide
Process Outline
FDM (Fused Deposition Modeling) Utilizing the BST 1200 Printer in the Learning Factory.
3-D Printing Utilizing the ZCorp Printer in the SALA (Stuckman Family) Building.
III. Conclusions / Lesson Learned
Troubleshooting/Tips:
Note: For best results read the Troubleshooting/Tips page prior to printing your 3D model.
Problem: The .STL file will not open, or when it does it is incorrect, such as a bunch of random points everywhere.
Solution: Verify that the .STL file was created from Revit, 3D CAD or FormZ.
Problem: When I printed the model it broke easily.
Solution: The electronic model should be created to the dimensions you actually want the final product. Try to avoid scaling, though if scaling is required, scale the model before converting to a .STL format. Try to draw all parts of the models to at least 1/16” thick – and thicker if it supports the structure.
Problem: The model turned yellow after I finished it.
Solution:
For the FDM Process: Ensure that the ultrasonic bath is clean.
For the ZCorp Printer: Use Z-Bond 101 to finish the model for best results and use a light coat for best results. If you choose to use clear spray paint, use a light coat to prevent discoloration.
Problem: My support structure did not completely dissolve in the ultrasonic bath.
Solution: Use an exacto-knife to cut away the remaining supports. It is also recommended breaking away the non-intricate supports prior to the ultrasonic bath.
Frequently Asked Questions (FAQ's):
Q: How much does it cost to construct a model?A: The FDM process cost $8.00/in3. The ZCorp Printer cost approximately $4.00/in3 (it is a function of the binder quantity).
Q: How long does it take to construct the model?
A: The FDM process takes approximately 45 minutes/in3 of model, and then another 45 minutes/in3 in the ultrasonic bath. The ZCorp Printer takes approximately 4 hrs to construct an 8” x 8” model.
Q: What is the benefit of using this technology over, let's say, chipboard model construction?
A: The 3D printing technologies allow for smaller model construction capabilities directly from CAD models, saving time and providing better results. The smaller construction tolerances of 0.004 inch is beneficial for constructing smaller building models that are to be a part of a site plan, also to provide greater detail on a larger sized model, allowing for the window sills, mullions, roof details, stairs, etc... to be constructed.
Contact Information:
For additional information on the ZCorp Printing process, including printing availability and costs, please contact the following:
Jamie Heilman
Architecture Department
0128 Stuckeman Family Building
jrh225@psu.edu
For additional information on the FDM Printing process, including printing availability and costs, please contact the following:
Carson M Baird
Engineering Department
Superviser of Engineering Labs
0101 Engineering Services
cxb290@psu.edu
For additional information on the Wikispaces used to create this website, please contact the following:
Dragana Nikolic
Architectural Engineering Department
Grad Student
Engineering Unit B
dun113@psu.edu
IV. Reference Sources